Friction material

ABSTRACT

A friction material comprising: (a) at least one lubricant, wherein the at least one lubricant includes an amount of graphite, and wherein at least about 30 percent by weight of the graphite has a particle size of greater than about 500 microns using a sieve analysis; (b) at least one metal containing constituent for imparting reinforcement, thermal conductivity, and/or friction when the friction material is brought into contact with a movable member, wherein the at least one metal containing constituent includes iron and an iron containing compound; (c) a micro-particulated material; (d) one or more filler materials; (e) optionally at least one processing aid; (f) a balance being an organic binder, wherein the organic binder has less than 1 percent by weight of free phenol; wherein the friction material is free of asbestos and substantially devoid of copper.

FIELD

The present teachings relate to a material composition of a brake padand/or brake shoe that provides increased braking performance andimproves the life of the rotor or drum respectively.

BACKGROUND

The present teachings are predicated upon providing a friction materialfor use in a brake system (e.g., a disc brake system, a drum brakesystem, or a combination of both) for use with vehicles. For example,the brake system may be used with almost any vehicle (e.g. car, truck,bus, train, airplane, or the like). Alternatively, the brake system maybe integrated into assemblies used for manufacturing or other equipmentthat require a brake such as a lathe, winder for paper products orcloth, amusement park rides, wind turbines, or the like. However, thepresent teachings are most suitable for use with a passenger vehicle(e.g., a car, truck, sports utility vehicle, or the like).

Generally, a braking system includes a rotor, a caliper body, a supportbracket, an inboard brake pad, and an outboard brake pad that are onopposing sides of the rotor. Typically, the inboard brake pad, theoutboard brake pad, and the rotor each include planar friction surfacesso that when the brake pads are in contact with the rotor a frictionforce is generated. The caliper body further includes one or morefingers, one or more piston bores, and a bridge that connects the one ormore fingers to the piston bore or two opposing piston bores together.The piston bore houses a piston. The piston bore has a bore axis thatthe piston moves along during a brake apply and a brake retract. Thepiston bore may include a fluid inlet, a closed wall, a front opening,and a cylindrical side wall that includes a seal groove located near thefront opening. Typically, the fluid inlet is located in the closed wallof the piston bore so that when pressure is applied the fluid will flowinto the piston bore. During a pressure apply the fluid will push thepiston towards the front opening and into contact with a brake pad thatgenerally includes a pressure plate and friction material with a planarsurface and the friction material will contact a planar surface of therotor on one side and an opposing brake pad will contact the planarsurface of the rotor on an opposing side creating friction to stoprotation of the rotor and any component connected to the brake system.

Another type of braking system includes two brake shoes in the hat ofthe rotor and/or drum so that when a braking force and/or parking brakeforce is desired the brake shoes are moved into contact with an innersurface of the hat of the rotor (e.g., a drum-in-hat brake system)and/or drum (drum brake system). Typically, brake shoes pivot on one endand have a link on an opposing end that separates the brake shoes sothat the brake shoes are moved into contact with an opposing surface togenerate a friction force. The link is connected to a pressure plate oneach of the brake shoes so that friction material exposed on thepressure plates directly contacts a surface of the drum and/or hat togenerate a friction force.

During these friction events the friction members (e.g., brake pad orbrake shoe) contacts a moving part (e.g., rotor or drum respectively)and the friction material gradually slows the moving part until acomplete stop is achieved. During the contact between the frictionmaterial and the moving part wear occurs so that a portion of thefriction material, moving part, or both gradually becomes worn overtime. The speed at which the friction material and moving part wear maybe increased or decreased based upon the composition of each. Thecomposition of the friction material may be adjusted to increase oneproperty which may result in a decrease in another property. Theseproperties may be balanced in order to provide a friction material thatachieves predetermined braking characteristics.

Examples of some friction materials are disclosed in U.S. Pat. Nos.7,297,728; 8,172,051; and U.S. Patent Application Publication Nos.2002/0169231; 2004/0146702; 2006/0151268; 2007/0219289; and 2008/156226and U.S. International Application Nos. WO99/53215; WO2011/049576; andWO2013/048627 all of which are expressly incorporated herein byreference for all purposes. What is needed is a friction material thatprovides a high level of braking without deteriorating and/ordeteriorating the moving part. What is needed is an improved frictionmaterial that generates a high level of friction without creating alarge amount of brake dust or brake powder. It would be attractive tohave a friction material that is bonded together by a material that bothkeeps all of the materials together but also assists in creatingfriction.

SUMMARY

One possible embodiment of the present teachings include: A frictionmaterial comprising: (a) at least one lubricant, wherein the at leastone lubricant includes an amount of graphite, and wherein at least about30 percent by weight of the graphite has a particle size of greater thanabout 500 microns using a sieve analysis; (b) at least one metalcontaining constituent for imparting reinforcement, thermalconductivity, and/or friction when the friction material is brought intocontact with a movable member, wherein the at least one metal containingconstituent includes iron and an iron containing compound; (c) amicro-particulated material; (d) one or more filler materials; (e)optionally at least one processing aid; (f) a balance being an organicbinder, wherein the organic binder has less than 1 percent by weight offree phenol; wherein the friction material is free of asbestos andsubstantially devoid of copper.

The present teachings may include a combination of one or more of thefollowing: wherein the one or more fillers include at least onefunctional filler that enhances friction, reduces noise, and improveswear; wherein the at least one functional filler is rubber or cashew;wherein the one or more fillers include at least one non-functionalfiller; wherein the at least one non-functional filler is a barite,calcium carbonate, or both; wherein the one or more fillers include atleast one functional filler and at least one non-functional filler andthe at least one non-functional filler does not affect functionalcharacteristics of the functional filler; wherein the one or morefillers include rubber dust, a barite, cashew nut dust, or a combinationthereof; wherein the graphite includes a natural graphite, a syntheticgraphite, or both; wherein an amount of the iron containing compound byweight exceeds an amount of the lubricant; wherein one of the at leastone lubricant is tin sulfide; wherein the tin sulfide is present in anamount from about 1 weight percent to about 10 weight percent andpreferably about 2 weight percent to about 5 weight percent of thefriction material; wherein the fibers are extruded and chopped or shavedor otherwise cut in predetermined sizes; wherein the at least one metalcontaining constituent includes magnesium oxide, aluminum, a mineralfiber, or a combination thereof; wherein the friction material issubstantially free of steel, and preferably is free of steel; whereinthe micro-particulated material has a particle size of about 500 micronsor less; wherein the micro-particulated material is substantially purehaving metal impurities in an amount of about 100 ppm or less; whereinthe at least one processing aid mechanically entangles with particles ofthe friction material in the green state so that the green statefriction material is bound together; wherein the processing aid is anaramid pulp; wherein the processing aid is present in an amount fromabout 1 percent by weight to about 15 percent by weight, and morepreferably from about 3 percent by weight to about 10 percent by weightof the friction material; wherein the organic binder includesformaldehyde in an amount of about 1 percent by weight of the organicbinder; wherein the organic binder is substantially free of freeformaldehyde; wherein the friction material is formed in a green stateand then cured to a final state; wherein the metal sulfide is present inan amount from about 12 weight percent to about 30 weight percent of thefriction material; wherein a ratio of the graphite to the ironcontaining compound is about 3:2; wherein the iron containing compoundis a powder having a particle size of about 40 microns or less,preferably about 20 microns or less, or more preferably between about 10microns and about 1 micron; wherein the micro-particulated materialincludes at least one metal selected from zinc, calcium, or molybdenumand is in the form of an oxygen containing compound (e.g., oxide orphosphate); wherein the particle size of the lubricant controlscompressibility of the brake pad during braking; or a combinationthereof.

The present teachings provide a friction material that provides a highlevel of braking without deteriorating and/or deteriorating the movingpart. The present teachings provide an improved friction material thatgenerates a high level of friction without creating a large amount ofbrake dust or brake powder. The present teachings provide a frictionmaterial that is bonded together by a material that both keeps all ofthe materials together but also assists in creating friction.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional perspective view of a brake system;

FIG. 2 is a perspective view of a brake pad including friction material;and

FIG. 3 is an exploded view of a drum brake system including brake shoes.

DETAILED DESCRIPTION

The explanations and illustrations presented herein are intended toacquaint others skilled in the art with the invention, its principles,and its practical application. Those skilled in the art may adapt andapply the invention in its numerous forms, as may be best suited to therequirements of a particular use. Accordingly, the specific embodimentsof the present invention as set forth are not intended as beingexhaustive or limiting of the teachings. The scope of the teachingsshould, therefore, be determined not with reference to the abovedescription, but should instead be determined with reference to theappended claims, along with the full scope of equivalents to which suchclaims are entitled. The disclosures of all articles and references,including patent applications and publications, are incorporated byreference for all purposes. Other combinations are also possible as willbe gleaned from the following claims, which are also hereby incorporatedby reference into this written description.

The teachings herein relate to one or more improved friction membersthat work in unison to provide improved braking performance. The one ormore friction members may be two or more complementary friction membersthat are moved into contact to form a brake apply. The one or morefriction members may be a brake pad, a brake shoe, or both. The one ormore friction members when installed in a system preferably include oneor more movable members (e.g., a rotational member) and one or morefriction member that are complementary to each other to create afriction force. The movable members may be a rotor, a drum, a hat of arotor, or a combination thereof. The friction members may be a brakepad, a brake shoe, or both. The one or more friction members may beinstalled in a brake system. The brake system may be a disc brakesystem, a drum brake system, a drum-in-hat brake system, or acombination thereof. The brake systems taught herein may include one ormore brake pads or brake shoes, preferably two or more brake pads orshoes, and even a plurality of brake pads or shoes.

The brake pads, brake shoes, or both (hereinafter friction members)function to create a braking event. The friction members may function tomove from a running state to an apply state so that a friction force iscreated. Each friction member may include a friction plate and afriction material.

The pressure plate may function to connect to a friction material sothat a braking force may be created, the pressure plate may connect thepressure member to a brake system, the pressure plate may move thefriction material so that a braking force is generated, or a combinationthereof. The pressure plate may provide support for the frictionmaterial, provide a point of contact with other brake components, apoint for moving the brake pad to create a brake apply, or a combinationthereof. The pressure plate may be made of any material so that thepressure plate provides support to friction material, assists inproducing a friction force during braking, or both. The pressure platemay be made of metal, a formable material, a stampable material, acomposite material, a material with sufficient rigidity to providesupport to a friction material during a braking event, or a combinationthereof. The pressure plate may have a complementary shape to thefriction material, the pressure plate may be flat, arcuate, have a flatsurface and be generally arcuate, include one or more recesses forreceiving a connector, include one or more recesses for receivingfriction material, or a combination thereof. The pressure plate mayinclude one or more connection features so that the pressure plate maybe included in a brake system.

The friction material may function to assist in creating a brakingforce. The friction material may contact a movable member and reduce,eliminate, or both movement of the movable member. The friction materialmay function to be a point of contact between the pressure member and amovable member (e.g., a rotor, drum, rotational member). The frictionmaterial may be applied to the pressure plate using any method and/ormaterial. The connection between the friction material and the pressureplate may be a mechanical connection (e.g., a rivet, a projection, abolt, a fastener, peened, the like, or a combination thereof), achemical connection (e.g., adhesive, epoxy, bonding agent, the like, ora combination thereof), or a combination of both. The friction materialmay be asbestos free, copper free, or both. The friction material mayinclude basalt fibers. The friction material may be compressed materialsthat are connected to a pressure plate. Preferably, the frictionmaterial is a composite of different materials that are compressedtogether to form a friction material. The composite material may includeone or more lubricants, one or more metal containing constituents, oneor more micro particulated materials, one or more filler materials, oneor more processing aids, one or more binders, or a combination thereof.

The lubricant may be a dry lubricant, a solid lubricant, or both. Thelubricant may be a liquid lubricant or may be provided in liquid form.The lubricant may have a layered structure. The lubricant may have anon-layered structure. The lubricant may include one or more atomsselected from, sulfur, nitrogen, carbon, boron, and fluorine. Thelubricant may include a metal. The particle size of the lubricant maycontrol compressibility of the brake pad. The lubricant may be providedin a form of a plurality of individual discrete elements (e.g., aspowder particles, fibers, flakes, or other elements), either or both maybe provided as having a maximum element size when subjected to sievetesting of no greater than about 1000 microns, preferably about 750microns, or more preferably about 500 microns measured using a sieveanalysis. The lubricant may have a particle size ranging from about 1micron to about 2500 microns, preferably from about 5 microns to about1000 microns, and more preferably about 10 to about 500 microns measuredusing a sieve analysis. Most preferably the lubricant may have aparticle size ranging from about 200 microns to about 450 microns. Thelubricant may have a particle size distribution where the medianparticle size when sieve testing, by weight, is between about 250microns to about 350 microns. The lubricant may be present in thefriction material at an amount of about 8 percent, about 10 percent byweight or more, about 12 percent by weight or more, about 15 percent byweight or more, or even about 18 percent by weight or more of thefriction material. The lubricant may be present in the friction materialin an amount of about 40 percent by weight or less, about 35 percent byweight or less, or about 25 percent by weight or less (i.e., betweenabout 8 percent and about 30 percent). The lubricant may be acombination of one or more materials and is preferably a plurality ofdifferent materials.

The lubricant may be one or more graphitic materials. For example, thelubricant may be a natural graphite, a synthetic graphite, a combinationof a natural graphite and a synthetic graphite (about 2 to about 6 partsby weight of natural graphite to about 6 to about 12 parts by weightsynthetic graphite (e.g., about 4 to 9)). Either or both of the naturalgraphite or the synthetic graphite may be provided in a form of aplurality of individual discrete elements (e.g., as powder particles,fibers, flakes, or other elements), either or both may be provided ashaving a maximum element size when subjected to sieve testing of nogreater than about 2500 microns, about 1000 microns, preferably about750 microns, or more preferably about 500 microns. Natural graphite mayhave a particle size ranging from about 1 micron to about 1000 microns,preferably from about 5 microns to about 750 microns, and morepreferably about 10 to about 500 microns measured using a sieveanalysis. When a natural graphite is used about 20 percent or more,about 30 percent or more, 40 percent or more, or even about 50 percentby weight of the total amount of graphite has a particle size of about500 microns or greater measured by sieve analysis. The graphite may havea particle size distribution where the median particle size when sievetesting, by weight, is between about 250 microns to about 350 microns.The graphite may be a course graphite and may have a particle sizedistribution of between about 300 microns and about 500 microns usingsieve analysis. The graphite may be a medium graphite and may have aparticle size distribution between about 200 microns and about 300microns using sieve analysis. The graphite may be a fine graphite andmay have a particle size distribution of about 50 microns and about 150microns using sieve analysis. The synthetic graphite may have a particlesize of about 500 microns or more but less than about 2500 microns, orless than about 2000 microns using a sieve analysis that are present inan amount of about 10 percent or more, about 20 percent by weight ormore, or about 30 percent by weight or more of the total lubricant. Thesynthetic graphite may have a particle size of about 500 microns or morebut less than about 2500 microns, or less than about 2000 microns usinga sieve analysis that are present in an amount of about 80 percent orless, about 70 percent by weight or less, or about 60 percent by weightor less of the total lubricant. The natural graphite may have a particlesize of between about 5 microns and 1000 microns, and preferably betweenabout 10 microns and about 500 microns using a sieve analysis. Either orboth of the natural or synthetic graphite may be regarded as a resilientgraphite. The resiliency of a graphite may be about 80% or more, about90% or more, preferably about 100% or more, about 120% or more, or evenabout 140% or more. The resiliency of a graphite may be about 200% orless, about 180% or less, or about 160% or less (i.e., preferablybetween about 100% and about 150%). Resiliency of the graphite ismeasured by compressing the graphite at a pressure of between about5,000 kPa to 70,000 kPa and the amount of spring back versus theoriginal shape is measured. The resilient graphite may have a porosityof about 1.0 g/cc or more, about 1.2 g/cc or more, or even about 1.4g/cc or more. The resilient graphite may have a porosity of about 3.0g/cc or less, about 2.5 g/cc or less, about 2.0 g/cc or less, or evenabout 1.8 g/cc or less. The resilient graphite may have a bulk densityof about 100 Kg/m³ or more, about 150 Kg/m³ or more, or about 200 Kg/m³or more. The resilient graphite may have a bulk density of about 600Kg/m³ or less, about 500 Kg/m³ or less, or preferably about 450 Kg/m³ orless. The resilient graphite may be present in the friction material ina sufficient amount so that the friction material is compressible todissipate energy during a braking event. Examples of suitable commercialgrades of lubricant are sold under the tradename RGC14A from SuperiorGraphite.

The lubricant may be one or more metal sulfides. The lubricant may beantimony sulfide, tin sulfide, tungsten sulfide, bismuth sulfide, ironsulfide, or a combination thereof. The antimony sulfide when present maybe present in an amount of about 1 percent or more, about 2 percent ormore, about 3 percent or more, about 4 percent or more, or even about 5percent by weight of the friction material. The antimony sulfide may bepresent in an amount of about 20 percent by weight or less, about 15percent by weight or less, or about 10 percent by weight or less of thefriction material (i.e., about 6 percent by weight). The frictionmaterial may be free of antimony sulfide, tin sulfide, or both. Theantimony sulfide may have a particle size of about 1 micron or more,about 5 microns or more, or about 10 microns. The antimony sulfide mayhave a particle size of about 100 microns or less, preferably about 75microns or less, or more preferably about 45 microns or less. The amountof lubricant selected may be sufficient to help minimize noise duringstandard braking conditions due to contact between a friction materialand a movable member. A sufficient amount of lubricant is added so thata noise of about 50 dB or less is created as measured by a simulatedL.A. city traffic test. By way of example, the lubricant may be presentin an amount about of at least about 1, 2, 3, 4, 5, 6 percent by weightof the friction material but in an amount not to exceed 15, 12, 10percent by weight of the friction material. If the lubricant is coke thecoke may be present in an amount of about 1 to 10 percent by weight andmore preferably about 2 to 5 percent by weight. Preferably, thelubricant may be coke, petroleum coke, tin sulfide, graphite, naturalgraphite, synthetic graphite, resilient graphite, or a combinationthereof. Preferably, the lubricant will include either a naturalgraphite or a synthetic graphite.

The friction material includes at least one metal containingconstituent. The at least one metal containing constituent may be anabrasive. The at least one metal containing constituent may haveabrasive characteristics (e.g., other materials such as a functionalfiller may also have abrasive characteristics). The metal containingconstituents may be a mineral that includes metal, an oxide, a puremetal, or a combination thereof. The metal containing constituents maybe naturally occurring, synthetic, or both. The metal containingconstituents may be a fiber, a powder, flake or a combination thereof.Preferably, the metal containing constituent may be in the form offibers (e.g., a mineral fiber). The fibers may be extruded, chopped,shaves, cut, or formed into a predetermined size. The metal containingconstituents may be a powder with a particle size of about 40 microns orless, preferably about 20 microns or less, more preferably about 10microns or less (e.g., between about 10 microns and 1 micron). The metalcontaining constituent may include magnesium, magnesium oxide, aluminum,aluminum oxide, a metal containing mineral fiber, iron, basalt, chromiumoxide, or a combination thereof. When basalt is used the basalt mayinclude magnesium oxide, aluminum oxide, or both. Preferably, iron isthe greatest amount of metal containing constituent. The iron may be inthe form of fibers. The fibers may be extruded, chopped, shaves, cut, orformed into a predetermined size. The iron may be a powder. The pureiron constituent to powder constituent may have a ratio. The ratio ofpure iron to iron powder may be about 1:1 or more, 2:1 or more, about3:1 or more. The ratio of pure iron to iron powder may be about 1:2 ormore or about 1:3 or more. All of the iron may be pure iron (i.e., 100percent), all of the iron may be an iron powder (i.e., 100 percent). Theiron may be pure iron or an iron oxide (e.g., magnetite). When magnetiteis present the magnetite may be present in an amount of about 4 percentby weight or more, 6 percent by weight or more, about 8 percent byweight, 10 percent by weight or more, 12 percent by weight or more, oreven about 15 percent by weight or more of the total weight of thefriction material. When magnetite is present the magnetite may bepresent in an amount of about 30 percent or less by weight, about 25percent or less by weight, or preferably about 20 percent by weight orless of the total weight of the friction material. The iron may be Fefiber, Fe₂O₃, Fe₃O₄, or a combination thereof. A ratio of iron to ironcontaining compounds may be present in the friction material of about1:1 or more, about 1:2 or more, about 1:3 or more, or even about 1:4 ormore. The ratio of iron to iron containing compounds may about 1:1 orless, about 1:0.5 or less, or about 1:0.33 or less. For example, theiron to iron containing compound may be present in an amount of about1:1.25 and in another example, the ratio of iron to iron containingcompound may be about 1:0.66. The metal containing constitute may not becopper, bronze, or a copper containing component. The metal containingconstituent is a substantially copper free (i.e., about 0.5 percent byweight or less). The metal containing constituent may be substantiallydevoid of copper (i.e., about 2 percent by weight or less). Preferably,the metal containing constituent includes zero copper by weight of thetotal weight of the friction material. The metal containing constituentmay be substantially devoid of steel (i.e., about 2 percent by weight orless). The friction material may be substantially free of steel (i.e.,about 0.5 percent by weight or less). Preferably the friction materialis free of steel that has a Brinnell hardness of about 250 or more.

The one or more metal containing constituents (i.e., total amount ofmetal containing constituents in the friction material) may be presentin the friction material in an amount of about 2 percent by weight ormore, about 4 percent by weight or more, preferably about 6 percent byweight or more, more preferably about 10 percent by weight or more, oreven more preferably about 12 percent by weight or more. The one or moremetal containing constituents (i.e., total amount of metal containingconstituents in the friction material) may be present in the frictionmaterial in an amount of about 55 percent by weight or less, about 50percent by weight or less, or about 45 percent by weight or less. Theone or more metal containing constituents may be present in a sufficientamount so that under normal braking conditions the friction material hasa coefficient of friction of about 0.3 or more, about 0.35 or more about0.4 or more, about 0.45 or more, or even about 0.5 or more. The one ormore metal containing constituents may be present in a sufficient amountso that under normal braking conditions the friction material has acoefficient of friction of about 0.75 or less, preferably about 0.65 orless, more preferably about 0.55 or less. The friction material mayinclude a sufficient amount of metal containing constituents that thefriction material has a Brinnell hardness of about 250 HB or less. Themetal containing constituents may have a Brinnell hardness of about 750HB or less, preferably about 500 HB or less, more preferably about 300HB or less, or most preferably about 250 HB or less. The metalcontaining constituents may have a Brinnell hardness of about 50 HB ormore, about 75 HB or more, or even about 100 HB or more. Preferably, themetal containing constituents have a Brinnell hardness of 400 HB orless, and more preferably about 250 HB or less. The friction materialmay include a sufficient amount of metal containing constituent so thatthe thermal conductivity of the friction material is about 1 W/mK ormore, about 2 W/mK or more, about 3 W/mK or more, or even about 4 W/mKor more. The friction material may include a sufficient amount of metalcontaining constituent so that the thermal conductivity of the frictionmaterial is about 10 W/mK or less, preferably about 7 W/mK or less, ormore preferably about 5 W/mK or less.

The friction material may include one or more micro-particulatedmaterials. A sufficient amount of micro-particulated materials may bepresent in the friction material to prevent the friction material fromsticking to other metallic components (e.g., disc or drum). Preferably,the micro-particulated materials are present in a sufficient amount toprevent or inhibit galvanic corrosion so that the friction material doesnot oxidize, the brake components do not stick together, or both. Forexample, when the brake is used as a parking brake and the frictionmaterial is moved into contact with a drum or rotor and maintained inthat position for an extended amount of time the micro-particulatedmaterials inhibit the friction material from sticking to the drum orrotor so that upon the parking brake release free movement is restored.The micro-particulated material may be a multi-functional material. Themicro-particulated material may provide friction (i.e., increase thecoefficient of friction), provide hardness, resist in corrosion, or acombination thereof. The micro-particulated material may resistcorrosion in one or more of the metal containing constituents. Themicro-particulated material may provide the same function as the metalcontaining constituent (i.e., friction) as well as inhibit corrosion.The micro-particulated material may include 1, 2, 3, 4, or more metalsthat may form a compound. The micro-particulated material may include aphosphate or a silicate. The micro-particulated material may be anoxygen containing compound. The one or more micro-particulated materialmay include a metalloid. The metalloid may be phosphorous. Themicro-particulated material may include a metalloid and oxygen incombination with one or more metals. The micro-particulated material maybe a mineral (i.e., natural, synthetic, or both). Preferably, themicro-particulated material is a zinc containing compound, zinc, orboth. More preferably, the micro-particulated material is asubstantially pure metal (i.e., has metal impurities in an amount ofabout 100 ppm or less). For example, the micro-particulated material issubstantially pure zinc metal powder. The micro-particulated materialmay include at least one metal selected from zinc, calcium, ormolybdenum and is in the form of an oxygen containing compound (e.g.,oxide or phosphate). The micro-particulated materials may be a zincaluminum orthophosphate hydrate, zinc orthophosphate hydrate, a zinccalcium strontium aluminum orthophosphate silicate hydrate, a zincphosphomolybdate, or a combination thereof. An example of a commerciallyavailable micro-particulated material is sold under the trade nameHeucophos® ZPA by Heubach. The micro-particulated material may have aparticle size of about 500 microns or less, preferably about 250 micronsor less, more preferably about 100 microns or less. Themicro-particulated material may have a particle size of about 50 micronsor less, preferably about 40 microns or less, preferably about 25microns or less, or more preferably about 15 microns or less. Themicro-particulated material may be present in an amount of about 0.1percent by weight or more, about 0.3 percent by weight or more, about0.5 percent by weight or more, or even about 1 percent by weight or moreof the friction material. The micro-particulated material may be presentin an amount of about 2 percent by weight or more, about 3 percent byweight or more, about 5 percent by weight or more, or even about 7percent by weight or more of the friction material. Themicro-particulated material may be present in an amount of about 25percent by weight or less, about 20 percent by weight or less, about 15percent by weight or less, or preferably about 10 percent by weight orless of the friction material (i.e., in an amount of between about 0.3percent by weight and 10 percent by weight).

The one or more filler materials may be present in a sufficient amountso that the fillers enhance friction, reduce noise, improved wear, or acombination thereof. The friction material may include a sufficientamount of filler so that the fillers affect the pore size distributionof the pad so that gases, fluids, or both can escape from the frictionmaterial during a braking event. The fillers may provide porosity,compressibility, an area of reduced density, or a combination thereof.The fillers may be softer than the other constituents of the frictionmaterial so that during a braking event the fillers allow the brake padto compress. The volume of the fillers may be reduced during a brakingevent and so that the friction material has some compressibility. Thefillers may conduct heat, extend from one side of a crack in thefriction material to a second side of a crack in the friction material,prevent brittleness in the friction material, provide strength to thefriction material upon repeated thermal cycling so that the frictionmaterial does not have thermal brittleness, or a combination thereof.The fillers may be a barite (baryte), calcium carbonate, titaniumdioxide, rubber, cashew nut dust, ceramic fiber fillers, mica,wollastonite, rockwool, perlite, vermiculite, a titanate, or acombination thereof. Preferably, the ceramic fibers. The fillers may befree of antimony, titanium dioxide, a titanate, or a combinationthereof. Preferably, the fillers are free of ceramic fillers having aparticle size of about 1 micron or less and preferably is free ofnanoparticles. More preferably, the fillers are not a bioinsolubleceramic fiber (i.e., the friction material is free of bioinsolubleceramic materials). The friction materials may be free of SiO₂, Al₂O₃,Al₂—SiO₂, Al₂O₃—SiO₂—ZrO₂, or a combination thereof. Preferably, thefriction material is free of fillers that are bioinsoluble fibers ornanoparticles. The one or more fillers may be a functional filler, anon-functional filler, or both.

Preferably, the friction material includes at least one non-functionalfillers. The friction material may include at least one functionalfiller. The non-functional filler may be a barite (baryte), calciumcarbonate, wollastonite, rockwool, perlite, vermiculite, or acombination thereof. The non-functional fillers may not change thehardness, coefficient of friction, or both. For example, thenon-functional fillers may not change the hardness of the frictionmaterial or be hard enough so that during a braking event the fillersassist is braking a moving member. In another example, thenon-functional fillers may not increase the coefficient of friction orcontribute to the coefficient of friction of the fiction material. Thenon-functional fillers may be used in conjunction with functionalfillers. The non-functional fillers may not have any effect on thefunctional fillers.

The functional fillers may have a sufficient hardness that the fillerscreate friction. The functional fillers may contribute to the brakingcharacteristics of the friction material. The functional fillers mayincrease the coefficient of friction or have a hardness that changes thecoefficient of friction of the friction material. Functional fillers maybe titanium dioxide, rubber dust, cashew nut dust, sodium molybdate,calcium fluoride, zinc powder, a titanate, a metatitanate,orthotitanate, or a combination thereof. The titanate may be a potassiumhexatitanate powder, strontium titanate, lithium titanate, bariumtitanate, aluminum titanate, sodium titanate, calcium titanate,potassium titanate, or a combination thereof. Preferably, the frictionmaterial is free of a titanate. The fillers may be present in an amountof about 1 percent by weight or more, about 5 percent by weight or more,about 10 percent by weight or more, or about 15 percent by weight ormore. The fillers may be present in an amount of about 75 percent byweight or less, preferably about 60 percent by weight or less, or about50 percent by weight or less of the friction material (i.e., betweenabout 5 percent by weight to about 60 percent by weight). The functionalfiller may comprise about 40 percent by weight or more, about 50 percentby weight or more, about 60 percent by weight or more, or preferablyabout 65 percent by weight or more of the total weight of the filler(i.e., the non-functional filler may be about 33 percent by weight andthe functional filler may be about 67 percent by weight of the totalweight of filler).

The friction material may include one or more processing aids. Theprocessing aids may be present in a sufficient amount so that theprocessing aids create entanglement within the friction material in agreen state. The processing aids may create mechanical entanglement inthe green state, a cured state, or both. The processing aids may bindthe friction material, bind the materials of friction material, or bothin the green state. The processing aids may be aramid pulp, cellulosepulp, acrylic pulp, or a combination thereof. The processing aids may bepresent in an amount of about 1 percent by weight or more, about 5percent by weight or more, about 10 percent by weight or more, or evenabout 12 percent by weight or more. The processing aids may be presentin an amount of about 20 percent by weight or less, about 15 percent byweight or less, or even about 12 percent by weight or less of thefriction material (i.e., between about 3 percent by weight and about 10percent by weight).

Binder may function to combine together and hold together the one ormore materials of the friction material in a green state, a cured state,or both. The binder may function to resist wear during a braking event.The binder may prevent degradation of the friction material due tocontact with the environment, with a moving member, or both. The bindermay assist in creating a braking force, a braking event, or both. Thebinder may be a phenolic resin. The binder may be an organic binder. Thebinder may be present in an amount of about 3 percent or more, about 4percent or more, about 5 percent or more, about 6 percent or more, about7 percent or more, about 8 percent or more, or even about 10 percent ormore by weight of the total weight of the friction material. The bindermay be present in an amount of about 30 percent or less, about 25percent or less, or about 20 percent or less. The binder may besubstantially free of free phenol (i.e., less than about 1 percent byweight of the organic binder in a green state, in a cured state, or bothis a free phenol). The binder may be substantially free of formaldehyde(i.e., less than about 1 percent by weight of the organic binder in agreen state, in a cured state, or both is formaldehyde). The freephenol, the formaldehyde, or both may be present in an amount of about0.5 percent by weight or less of the organic binder. Preferably, thebinder is free of free phenol, formaldehyde, or both (i.e., not eventrace amounts are found in the friction material). Examples ofcommercially available low phenol resins are available from the HexionCorporation under the tradenames Durite FD-900A and Cellobond J1011H.

Friction materials in accordance with the materials are made by mixingthe ingredients in a Eirich mixer for about 4 minutes, while taking careto prevent clumping or balling of ingredients. The ingredients are movedfrom the Eirich mixer into a die that is room temperature to preform theingredients creating a frictional material in a green state. Theingredients, in a green state, are moved from the die into a hot diewhere the friction material is pressed at about 20 KPa and heated untilthe melting point of the resin is achieved. The friction material onceheated to the melting point of the resin is then removed from the heatand allowed to sit for 4 minutes forming a cured near net shape part.The cured near net shape part is then placed in a post cured oven tocompletely cure oven at about 200° C. for about 3 hours.

The friction material is tested for resulting characteristics. Thefriction material is then tested for performance (i.e., coefficient offriction of the friction material), wear life, brake torque variation,and corrosion stiction test. The corrosion stiction test is performed asper JIS D4414 to identify if the friction material sticks to the drum orrotor when maintained in a closed position.

FIG. 1 illustrates a brake system 2 that is a disc brake system 10. Thedisc brake system 10 includes a caliper 12 and a support bracket 14 thatconnects the caliper 12 to a component that needs braking such as avehicle (not shown). The caliper 12 includes a piston bore 16 and apiston 18 that moves within the piston bore 16. A pair of opposing brakepads 20 are located within the disc brake system 10.

FIG. 2 is a perspective view of a brake pad 20 including a pressureplate 22 and friction material 24.

FIG. 3 illustrates an exploded view of a drum brake 40. The drum brake40 includes a support plate 42 with lands 44 that assist in connectingthe brake shoes 50 within a component that needs braking such as avehicle (not shown). The brake shoes 50 are connected at a top end by alink 46 that moves and a bottom end by a spring 48 that also permits thebrake shoes 50 to move. The brake shoes 50 include a pressure plate 52and friction material 54.

EXAMPLES

A B C D E F G H I J K L M N Phenolic Resin 9 9 7.5 8   9.5 8 10  9 5 6 78 8 8 Rubber Dust 5 4 4 2 — 5 1 8 6 2 3 6 2 2 Cashew Nut Shell Friction3 6 5 5 4   6.5 8   4.5 6 4 2 6 4 4 Dust Petroleum Coke 4 3 4 6 3 3 7 65 — 3 5 1 3 Tin Sulfide 2 3 4 4   2.5 4 — 1 3 4 4 5 4 3 Molybdenumdisulfide 8 3 — 3 — 2 5 1 2   3.5 3 4 6 3 Potassium hexatitanate — — 910  10  — 2 6 4 3 — — 1 — powder Zinc Aluminum 5 — 5 6 7 6   5.5 1 1 — 66 4 6 Orthophosphate hydrate Aramid pulp 3 4 4 3   3.5 3 5 2 4   4.5 3 4  2.5 3 Zinc powder 6 6 5 4 5 3 7 6 3 7 4 6 5 6 Iron fiber 5 6 3 4 5 6 47 2 3 8 4 12  5 Magnetite 5 9 6 8 9 10  9 9 12  10  3 9 — 3 MineralFiber 6 6 — — 6 5 3 2 4 5 — 4 5 3 Graphite 6 4 6 6 5 5 9 2 3 7 8 5 4 3Synthetic Graphite 4 7 7 6 3 4 2 8 4 6 5 3 2 7 Magnesium Oxide — 2 3 2 23 2 4 — 1 7 4 9 2 Monoclinic Zirconia 4 8 5 5 5 8 7 10  — 8 6 6 7 10 Barytes 5 7 7 — 2   1.5 — 2   2.5 3 5 — 4 7 Basalt — — — 3 5 2 5 — 6 2 24 3 4 Calcium Silicate 2 2 4 2   1.5 2 —   0.5   3.5 5 7 — 3 2 BismuthSulfide — — — 3 4 — — 4 5 5 2.5 3 2 4 Iron Sulfide 3 4 — — 3 4 5 — 6 4 —— 4 4 Zirconium Silicate 4 2 2.5 4 3 2   0.5 4 3 — 2 3 — 2 CalciumCarbonate 5.5 — 5 4 — 2 — 1 — 2 3 — 2 6 Sodium Molybdate 1.5 — — 2 2 2 1— 3 — 1 — 4 2 Calcium Fluoride 2 2 2 — — — — 2 3 — 3 2   1.5 — ManganeseSulfide 2 3 2 — — 3 2 — 4 5 2.5 3 — — Copper — — — — — — — — — — 0.5 — —— Asbestos — — — — — — — — — — — — — — *All of the values in the tableare weight percent unless otherwise stated.

The above are tested for meeting the following three requirements: (1)performance, (2) wear life, and (3) brake torque variation. Each of thefriction materials passed each of these three tests.

As used herein, unless otherwise stated, the teachings envision that anymember of a genus (list) may be excluded from the genus; and/or anymember of a Markush grouping may be excluded from the grouping.

Unless otherwise stated, any numerical values recited herein include allvalues from the lower value to the upper value in increments of one unitprovided that there is a separation of at least 2 units between anylower value and any higher value. As an example, if it is stated thatthe amount of a component, a property, or a value of a process variablesuch as, for example, temperature, pressure, time and the like is, forexample, from 1 to 90, preferably from 20 to 80, more preferably from 30to 70, it is intended that intermediate range values such as (forexample, 15 to 85, 22 to 68, 43 to 51, 30 to 32 etc.) are within theteachings of this specification. Likewise, individual intermediatevalues are also within the present teachings. For values which are lessthan one, one unit is considered to be 0.0001, 0.001, 0.01, or 0.1 asappropriate. These are only examples of what is specifically intendedand all possible combinations of numerical values between the lowestvalue and the highest value enumerated are to be considered to beexpressly stated in this application in a similar manner. As can beseen, the teaching of amounts expressed as “parts by weight” herein alsocontemplates the same ranges expressed in terms of percent by weight.Thus, an expression in the of a range in terms of “at least ‘x’ parts byweight of the resulting composition” also contemplates a teaching ofranges of same recited amount of “x” in percent by weight of theresulting composition.”

The components express their composition in a percent by weight. Eventhrough the compositions do not express a relative ratio betweencomponents such ratios are within the scope of the teachings. By way ofexample, if element A is in an amount of about 10 percent by weight andelement B is in an amount of about 2 percent by weight of the totalcomposition the teachings herein contemplate a ratio of about 4:1 for Ato B. Unless otherwise stated, all ranges include both endpoints and allnumbers between the endpoints. The use of “about” or “approximately” inconnection with a range applies to both ends of the range. Thus, “about20 to 30” is intended to cover “about 20 to about 30”, inclusive of atleast the specified endpoints.

The disclosures of all articles and references, including patentapplications and publications, are incorporated by reference for allpurposes. The term “consisting essentially of to describe a combinationshall include the elements, ingredients, components or steps identified,and such other elements ingredients, components or steps that do notmaterially affect the basic and novel characteristics of thecombination. The use of the terms “comprising” or “including” todescribe combinations of elements, ingredients, components or stepsherein also contemplates embodiments that consist of, or consistessentially of the elements, ingredients, components or steps.

Plural elements, ingredients, components or steps can be provided by asingle integrated element, ingredient, component or step. Alternatively,a single integrated element, ingredient, component or step might bedivided into separate plural elements, ingredients, components or steps.The disclosure of “a” or “one” to describe an element, ingredient,component or step is not intended to foreclose additional elements,ingredients, components or steps.

It is understood that the above description is intended to beillustrative and not restrictive. Many embodiments as well as manyapplications besides the examples provided will be apparent to those ofskill in the art upon reading the above description. The scope of theinvention should, therefore, be determined not with reference to theabove description, but should instead be determined with reference tothe appended claims, along with the full scope of equivalents to whichsuch claims are entitled. The disclosures of all articles andreferences, including patent applications and publications, areincorporated by reference for all purposes. The omission in thefollowing claims of any aspect of subject matter that is disclosedherein is not a disclaimer of such subject matter, nor should it beregarded that the inventors did not consider such subject matter to bepart of the disclosed inventive subject matter.

We claim:
 1. A friction material comprising: a. at least one lubricant,wherein the at least one lubricant includes an amount of graphite, andwherein at least about 30 percent by weight of the graphite has aparticle size of greater than about 500 microns using a sieve analysis;b. at least one metal containing constituent for impartingreinforcement, thermal conductivity, and/or friction when the frictionmaterial is brought into contact with a movable member, wherein the atleast one metal containing constituent includes iron and an ironcontaining compound; c. a micro-particulated material includesmolybdenum and is in the form of an oxygen containing compound; d. oneor more filler materials; e. optionally at least one processing aid; f.a balance being an organic binder, wherein the organic binder has lessthan 1 percent by weight of free phenol; g. wherein the frictionmaterial is free of asbestos and antimony and substantially devoid ofcopper.
 2. The friction material of claim 1, wherein the one or morefiller materials are present in an about from about 5 weight percent toabout 60 weight percent of the friction material.
 3. The frictionmaterial of claim 1, wherein the friction material is substantially freeof titanium dioxide, ceramic fiber filler, or a combination thereof, andthe antimony is antimony sulfide and the friction material is free ofantimony sulfide.
 4. The friction material of claim 1, wherein thefriction material is substantially free of titanium dioxide, ceramicfiller, or a combination thereof having a particle size of about 1micron or less.
 5. The friction material of claim 1, wherein thefriction material is substantially free of titanate.
 6. The frictionmaterial of claim 1, wherein the lubricant includes a metal sulfide thatis present in an amount from about 8 weight percent to about 30 weightpercent of the friction material.
 7. The friction material of claim 1,wherein a ratio of the lubricant to the at least one metal containingconstituent is about 2:1.
 8. The friction material of claim 1, whereinthe iron is in the form of extruded, chopped, or shaved fibers.
 9. Thefriction material of claim 1, wherein the iron and iron containingcompound is a largest amount by weight of the at least one metalcontaining constituents.
 10. The friction material of claim 1, whereinthe iron containing compound is a powder having a particle size of about40 microns or less.
 11. The friction material of claim 1, wherein the atleast one metal containing constituent is present in an amount fromabout 6 weight percent to about 45 weight percent of the frictionmaterial.
 12. The friction material of claim 1, wherein a ratio of theiron to the iron containing compound is about 1:2 by weight.
 13. Thefriction material of claim 1, wherein the metal containing constituentshave a hardness of about 250 or less on the Brinnell hardness scale. 14.The friction material of claim 1, wherein the friction material includesat least one multifunctional component that aids in resistance ofcorrosion and creating friction.
 15. The friction material of claim 1,wherein the micro-particulated material resists corrosion of the atleast one metal containing constituent.
 16. The friction material ofclaim 1, wherein the micro-particulated material further includes atleast one metal selected from zinc or calcium.
 17. The friction materialof claim 1, wherein the micro-particulated material is present in anamount from 0.3 weight percent to about 10 weight percent of thefriction material.
 18. The friction material of claim 1, wherein theorganic binder includes free phenol and free formaldehyde each in anamount of less than about 1 percent by weight of the organic binder in agreen state, in a cured state, or both.
 19. The friction material ofclaim 18, wherein the free phenol and the free formaldehyde are eachpresent in an amount of less than about 0.5 percent by weight of theorganic binder.
 20. The friction material of claim 1, wherein themicro-particulated material is zinc phosphomolydbate.
 21. The frictionmaterial of claim 1, wherein the one or more filler materials arecalcium fluoride.